SUZUKI TSS5OW SERVICE MANUALFOREWORD This service manual has been specially prepared to provide all the necessary information for the proper maintenance and repair of the TS50W. The TS5OW is a new type of motor- cycle that has many technical features such as: * Water cooled The TS5OW fits the needs of a wide variety of motorcycle users. Those who will be servic- jing this motorcycle should carefully review this manual before performing any repairs or services. This manual contains up-to-date information at the time of its issue. Latermade modifica- tion and changes will be explained to each SUZUK! distributor in respective markets, to whom you are kindly requested to make query about up dated information, if any. The TS50W motorcycles distributed in your country might differ in minor respects from the standard'specification and, if they do, it is because some minor modifications (which are of no consequence in most cases as far as servicing is concerned) had to be made to comply with the statutory requirements of your country. SUZUKI MOTOR CO.,LTD. Administration Department Overseas Service Division Quoting, copying or otherwise using any part of this manual without explicit authoriza- tion from Suzuki Motor Co., Ltd, is not permitted as all rights to the publication are reserved under copyright law.GROUP INDEX GENERAL INFORMATION PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES SERVICING ENGINE FUEL AND OIL SYSTEM COOLING SYSTEM ELECTRICAL SYSTEM CHASSIS mS ee SERVICING INFORMATIONINERAL INFORMATION CONTENTS 4 SERIAL NUMBER LOCATION SPECIAL FEATURE «---++-++---- FUEL AND OiL RECOMMENDATIONS:«-- SPECIAL MATERIALS -- oom PRECAUTIONS AND GENERAL INSTRUCTIONS -- SPECIFICATIONS 60500550 0.05500500s 000 sarenaey1.1 GENERAL INFORMATION SERIAL NUMBER LOCATIONS RIGHT SIDE FRAME NUMBER The frame serial number is stamped on the steering head pipe. LEFT SIDE ENGINE NUMBER The engine serial number is located on the left side of the crankcase.GENERAL INFORMA’ SPECIAL FEATURE TS50 COOLING SYSTEM The cooling system is composed of radiator, reservoir tank, radi coolant. The coolant flow cycle is shown and explained below. for hoses, water pump, thermostat, and Radiator t Thermostat Water pump ——— —= Cylinder — Cylinder head. -——— The coolant is fed by the water pump from the radiator to the circumference of the combustion chamber, it absorbs the heat generated in the combustion chamber, and it returns to the radiator via the thermostat. During passage through the radiator, the heat absorbed from the combustion chamber is released, the cool- ant is cooled, and then it flows again to the water pump. The thermostat changes the lift condition according to the temperature of the coolant. At a temperature of 65°C or less, the thermostat has no lift, and at a temperature of 80°C or more, fully- ‘open condition is reached. Reservoir tank Radiator Water pump1.3 GENERAL INFORMATIONGENERAL INFORMATION 14 FUEL, OIL AND COOLING SOLUTION RECOMMENDATIONS Be sure to use the specified fuel and oil. ‘The following are the specifications. FUEL Unleaded or low-lead type gasoline is recommend: ed. The gasoline should be at least 85 — 95 octane by the Research Method. If your engine pings, a regular grade of fuel, may be substitute. ENGINE OIL Use SUZUKI “CCI” oil or SUZUKI CCI super oil. They are formulated to give best engine perform- ance least combustion chamber deposits, least preignition, maximum spark plug life and best lubrication. If they are not available, a good quality TWO-STROKE OIL (non-diluent type) should be used. TRANSMISSION OIL Use a good quality SAE 20W/40 multi grade motor oil, FRONT FORK OIL Fork oil # 10.1.5 GENERAL INFORMATION COOLING SOLUTION Use an anti-freeze & Summer coolant compatible with aluminum radiator, mixed with led water only, at the ratio of 50 : 50. Water for mixing Use distilled water only. Water other than di water can corrode and clog the aluminum radiator. Anti-freeze & Summer coolant The coolant performs as rust inhibitor and water Pump lubricant as well as anti-freeze. Therefore, the coolant should be used at all times even though the atmospheric temperature in your area does not go down to freezing point. ‘Suzuki recommends the use of SUZUKI GOLDEN CRUISER 1200 anti-freeze & summer coolant, If this is not available, use an equivalent which is compatible with aluminum radiator. Required amount of water/coolant Solution capacity (total): 700 ml Water | 490 mi 30% + [Coolant | 210 mi 40% Water | 420 mi | Coolant 280 mi a | Water 350 mi Coolant | 350 mi CAUTION: Mixing of anti-freeze & summer coolant should be limited to 60%. Mixing beyond it would reduce its efficiency. If the anti-freeze & summer coolant mixing ratio is below 30%, rust inhibiting performance is gently reduced. Be sure to mix it above 30% even though the atmospheric temperature does not go down to freezing point.SPECIAL MATERIALS MATERIALS REQUIRED FOR MAINTENANCE ‘The materials shown are required for maintenance works on the Model TSSOW, and should be kept on hand for ready use. In addition, such standard materials as cleaning fluid, lubricants, etc., should also be available, Methods of use discussed in the test of this manual on later pages. GENERAL INFORMATION 15 19900-24240 Macerit Use Page Use Page © Oil seat 321 © Cushion lever 738 © Gear shift shaft | 327 bearing © Wheel bearing | 77 728 © steering bearing | 7-18 © Sprocket mounting | 7-26 ‘drum bearing | © Rear swingarm bush | 7 | 7235 SUZUKI | SUPER GREASE “A” | SUZUKI MOLY PASTE 99000-25010 99900-25140 Matching surface | 3:26 Te Front fork damper | 7-12 of erankease rod boit Front fork damper | 7-12 roa bolt SUZUKI BOND THREAD LOCK No. 12078 CEMENT 99000:31140 9900032040 Cam guide screw | 3.27 '@ Rotor nut 330 Paw lifter screw | 327 Countershat oaring retainer [THREAD Lock “1322” }29000:32060, | '20000:32110 t (Gear shite em Faces stopper bolt SUZUKI GOLDEN CRUISER 99000-24120 © Radiator THREAD LOCK 3038" : ee | xsiSPECIFICATIONS DIMENSIONS AND DRYMASS Overall length Overall width. Overall height Wheelbase . . Seat height . Dry mass... ENGINE ‘Type Intake system Number of cylinder. . . Bore .. SMOKE. see ee eee ene Piston displacement. Compression ratio Carburetor. . Air cleaner. . Lubrication system . TRANSMISSION Clutch..... Transmission . Gearshift pattern. Primary reduction Final reduction . Gear ratios, Low. 2nd 3rd. 4th . 5th . Top. Drive chain . GENERAL INFORMATION 1-2 - 2045 mm 810 mm - 1115 mm 1315 mm 260 mm 77 kg . Twostroke, water cooled . Piston and reed valve ot 41.0 mm 37.8 mm + 49cm? 86:1 MIKUNI VM185S, single - Polyurethane form element . SUZUKI “CCI” - Wet multi-plate type - 6-speed constant mesh . T-down, 5-up - 3.842 (73/19) = 3.833 (46/12) - 3.166 (38/12) - 2,000 (34/17) 1.500 (27/18) = 1,217 (28/23) 1.041 (25/24) - 0,923 (24/26) . DAIDO D.1.0.420 or TAKASAGO RK420, 120 links1-9 GENERAL INFORMATION ‘1:9 GENERAL INFORMATION CHASSIS Front suspension. Telescopic, oil damped Rear suspension. . . Full-floating suspension system Steering angle . Caster . Trail «6.2... Turning radius. 43° (right & left) 60° 50’ 13mm. - 2.2m Front brake. . Internal expanding Rear brake. Internal expanding Front tire size...... ves 250-21 4PR Rear tiresize....... 3.00-18 4PR ELECTRICAL Ignition type. - SUZUKI “PEI” Ignition tir - 22° B.T.D.C. at 6 000 r/min Spark plug. ... NGK BPRES or NIPPON DENSO W24EPR Battery . 12V 14.4 KC (4 Ah)/10 HR Generator . « Flywheel magneto Fuse ..... 15A Headlight. ++ 12V 25/25W Tail/Brake light. ++ 12V5.2/18.4W Turn signal light . . 12V 10W ‘Speedometer light 12V 1.7 Tachometer light. 121.7 Oil level indicator light . .. 12V3.4W Neutral indicator light. 12V 3.4W High beam indicator light . .12V1.7W Turn signal indicator light........ . 12V3.4W CAPACITIES Fuel tank including reserve 7.0L reserve 1.8L Engine oil tank . 1.2L Front fork oil... . 150.6 ml Transmission oil. a + 850 mi Cooling solution... .. betes + 700 mi * These specifications subject to change without notice.PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES CONTENTS PERIODIC MAINTENANCE SCHEDULE..-.--..-..-.-- MAINTENANCE AND TUNE-UP PROCEDURES: ---2:4 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended interval for all the required periodic service work necessary to keep the motorcycle operating at peak performance and economy. Traveled distance is expressed in terms of kilometer and hour, PERIODIC MAINTENANCE CHART = interval | Initial 1000 km | Ew om] xm 6 ‘ for | teen | amarante encase aera Battery I 1 a = Air lean = | Cylinder head, cylinder and muffler = = Removecerbon | — ‘Spark plug Pee 1 BEE i R - Tonition timing 1 1 = = Carburetor le fee ee Pet - Overhaul Oil pump EB A | 1 - - Fuel lines Replace every 4 years = c = ae Sra I - = Transmission oll ch = ch z Cooling solution (Change every 2 years Radiator hose ‘Change avery 2 years Engine bolts and nuts 1 1 = = Drive chain Inspect and clean every 1 000 km Brakes 4 1 I = = Tires 1 1 [ = = Steering I ' t | 5 a Front fork oil Zz ch aes hz Ch Chasis bolts and nuts 1 1 [ = a Note: 1: Inspect C: Clean Ch: Change : ReplacePERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 22 LUBRICATION CHART Rotating and rubbing parts must be lubricated periodically. Insufficient lubrication and severe damage may result. cause rapid wear LUBRICATION CHART ——— Interval me ——_EMIN' | Initia and every 6 000 km or 6 months | Every 12.000 km or 12 months Throttle cable Motor oil — Throttle grip = Grease Clutch cable Motor oil = ‘Speedometer cable = Grease ‘Speedometer gear box = : Grease “Tachometer cable eee eee ae Grease Drive chain a Motor oil every 1.000 km Brake pedal Grease or Brake cam shaft = ‘Steering stem bearing Grease every 2 ye WARNING: Be careful not to apply too much grease to the brake cam shaft. If grease gets on the linings, brake slippage will result, Lubricate exposed parts which are subject to rust, with either motor oil or SUZUKI super grease ‘A’ (99000-25010) whenever the motorcycle has been operated under wet or rainy conditions. Before lubricating each part, clean off any rusty spots and wipe off any grease, oil, dirt or grime.23 PERIODIC Mi TENANCE AND TUNE-UP PROCEDURES MAINTENANCE PROCEDURES BATTERY spect Initial 1 000 km (1 month) and Every 3 000 km (3 months) To check the electrolyte level and specific gravity, remove the battery from the motorcycle. ‘© Remove the seat. © Take off the frame cover. ‘© Remove the battery © lead wire and next @ lead wire. ‘© Remove the battery from the motorcycle. Electrolyte level © Inspect whether electrolyte level is between Lower level line (D) and Upper level line @) . © Add distilled water, as necessary, to keep the surface of the electrolyte above the Lower level line @ but not above the Upper level line @). For checking specific gravity, use a hydrometer to determine the charged condition. 09900 - 28403 Hydrometer Standard specific ee gravity ‘An S.G. reading of 1.24 (at 20°C) or under means that the battery needs recharging off the machine: take it off and charge it from a recharger. Charging the battery in place can lead to failure of the regulator/rectifier. © To install the battery, reverse the procedure described above. Ensen WARNING: When installing the battery lead wires, fix the Breather pipe ® lead first and © lead last. © Make sure that the breather pipe is tightly secured and undamaged, and is routed as shown in the figure.AIR CLEANER Clean Every 3 000 km (3 months) If the air cleaner element is clogged with dust, intake resistance will be increased with a resultant decrease in power output and an increase in fuel consumption. Check and clean the element in the following man. ner. © Remove the seat and left frame cover. © Unscrewing the screws and, take off the cleaner cover and element retainer. © Fill the washing pan of a proper size with non flammble cleaning solvent. Immerse the element in the cleaning solvent and wash it clean. © Squeeze the cleaning solvent out of the washed by pressing it between the palms of both hands. ‘© Immerse the element in motor oil, and squeeze the oil out of the element leaving it sightly wet with oil NOT! Do not twist or wring the element because it will tear or the individual cells of the ele- ment will be damaged. PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 24 CAUTION: Inspect the element carefully for rips, torn seams, et. If any damaged is noted, replace ‘the element with a new one. CYLINDER HEAD, CYLINDER AND MUFFLER Remove the carbon Every 6 000 km (6 months) Carbon deposits in the combustion chamber of the cylinder head and at the piston crown will raise the compression ratio and may cause preignition or overheating. Carbon deposited at the exhaust Port of the cylinder will prevent the flow of the exhaust, reducing the output. Remove the carbon deposits periodically. Be careful not to damage the surface of the combustion chamber and exhaust, Port when removing carbon,2.5 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES SPARK PLUG Inspect the Initial 1 000 km (1 month) and | Every 3.000 km (3 months) |_ Replace the Every 6 000 km (6 months) Remove the carbon deposits with a wire or pin and adjust the spark plug gaps 0.6 — 0.8 mm, measur- ing with the thickness gauge. 09900 - 20804 Thickness gauge When removing the carbon deposits, be sure to ‘observe the appearance of the plug, noting the ‘color of the carbon deposits. The color observed indicates whether the standard plug is suitable or not. If the standard plug is apt to get wet, a hotter plug should be used. If the standard plug is apt to over- heat (porcelain is whitish in appearance), replace with a colder one, IGNITION TIMING Inspect Initial 1.000 km (1 month) and Every 3000 km (3 months) the Remove the magneto cover and light cord to the high-tension cord. After starting the engine, aim the light from the timing light at the aligning mark () on the crank- case. Raise the engine r/min to 6000 r/min. At this time, the ignition timing is proper if the aligning mark @ is aligned to the line @) on the magneto rotor when the timing light flashes. ing 09900 - 27311 Timing light NIPPON [eee DENSO Hot type BPR7ES W22EPR Standard | BPRBES W24EPRPERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 25 If the ignition timing is not correct, adjust follow- ing procedure below. © Remove the rotor by using special tool. (refer to page 3-9) © Loosen the stator fitting screws. © Align the index line @ on the stator to the alignment line @ on crankcase. CARBURETOR Inspect Initial 1 000 km (1 month) and ] Every 3 000 km (3 months) Overhaul Every 12 000 km (12 months) Adjust the engine idle speed as follows. © Start the engine and allow it to warms up. NOTE: | ‘A warm engine means and engine which has been run averaging 50 km/h in top gear for 9 minutes. | © Turn the throttle stop screw (@ so that engine idle at 1 500 r/min. © Turn the pilot air screw @ in or out around 1/4 turn from the original setting (refer to page 8-8), The engine r/min will increase or decrease in accordance with the turning of the pilot air screw. Set this screw in a position that allows the engine to idle at the highest r/min, © Tur the throttle valve stop screw again and adjust the idle r/min at 1 150 ~ 1 450 r/min. T Idle r/min | 1.300 + 150 r/min2.9 PERIODIC MAINTENANCE AND TUNE.UP PROCEDURES TRANSMISSION OIL Change Initial 1 000 km (1 month) and Every 6 000 km (6 months) After a long period of use, the transmission oil will deteriorate and quicken the wear of sliding and interlocking surfaces. Replace the transmission oil periodically following procedure below. © Start the engine to warm up the engine oil, this, will facilitate draining oil. Shut off the engine. © Unscrew the oil filler cap @ and drain plug @, and drain the oil completely. © Tighten the drain plug. 15 —20N-m (1.5 —2.0 kgm) itening torque © Supply a good quality SAE 20W/40 multigrade motor oil. Capacity | 850 ml © Check the oil level with oil level screw @).PERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2-10 COOLING SOLUTION "Inspect the cooling solution level. ‘Change Every 2 years | WARNING: Do not remove the radiator cap or change the cooling solution when engine is still hot. Wait until it cools down, Sespection (Check the cooling solution level of the reservoir. The level should be between “LOW” level line and FULL” level line. f= the cooling solution level is below the “LOW” ‘evel line, remove the reservoir tank cap and fill “FULL” level line. Change ® Support the motorcycle by using jack or block. ® Remove the radiator cap and drain plug. Drain the coolant from radiator, engine side and re- servoir completely. ® Tighten the drain plug. * Fill the cooling solution in the radiator and reservoir. [ Capacity 700 mi RADIATOR HOSE Change Every 2 years Drain the cooling solution Loosen the clamp screw. Disconnect the radiator hose. . . . © Replace the radiator hose with a new one,2:13 PERIODIC MAINTENANCE AND TUNE.UP PROCEDURES 1000 km (1 month) and Every 3 000 km (3 months) Front Measure the clearance between the brake lever end and throttle grip when brake is fully applied. © Loosen the lock nut (D) and slide the adjuster @) on the front brake lever fully in. © Loosen the lock nut @ and slide the adjuster ance to 20 — 30 mm by sliding the adjuster @. Rear @ Loosen the lock nut () and adjust the brake pedal height #) to 10 mm by turning the ad- juster @ in or out. © Adjust the free travel to 20 — 30 mm by turning the adjuster @ .PERIODIC MAINTENANCE AND TUNE. ‘Brake shoe wear This motorcycle has brake lining wear limit indi- estor on the front and rear. As shown in Fig,, at ‘the condition of normal lining wear, the extension Sine of index mark on the brake cam shaft should be within the range embossed on the brake panel with brake on, To check wear of the brake lining perform follow- ing steps. © First check if the brake system is properly ad- justed. * While operating the brake, check to see that the extension line of the index mark is within the range on the brake panel. © If the extension line of the index mark is be- yond the range as shown in the Fig., the brake shoe assembly should be replaced with a new one as a set. TIRES Inspect Initial 1 000 km (1 month) and Every 3.000 km (3 months) TREAD CONDITION Operating the motorcycle with the excessively worn tires will decrease riding stability and con- sequently invite a dangerous situation. It is highly recommended to replace the tire when the remain- ing depth of tire tread reaches the following specifications. FRONT 3.0mm REAR 3.0mm If the tire pressure is too high or too low, steering will be adversely affected and tire wear increased. Therefore, maintain the correct tire pressure for ‘900d roadability or shorter tire life will result. COLD INFLA- FRONT REAR TION TIRE 180 kPa 175 kPa PRESSUnE 1.50 kg/em?_| 1.75 ka/em? WARNIN The standard tire fitted on this motorcycle is 250-21 4PR for front and 3.00-18 4PR for rear. The use of a tire other than the standard may cause instability. It is highly recommended to use a SUZUKI Genuine Ti ©) ‘The extension line of the index mark is within the range.STEERING | Anspect initia 1000 km (1 month) and Every 3 000 km (3 months) Steering should be adjusted properly for smooth manipulation of handlebars and safe running. Too stiff steering prevents smooth manipulation of handlebars and too loose steering will cause poor stability. Check to see that there is no play in the steering bearings. If any play can be found, adjust the steering as follows: © Support the motorcycle body and jack up the front wheel. ‘© Remove the radiator cover. © Detach the fuel tank. © Loosen the handlebars set bolts and take off the handlebar and ignition switch. © Loosen the steering stem head bolt. ighten or loosen the steering stem nut @ by the special tool @) so that the handlebars move smoothly. 09910-60611 | Steering stem nut wrench NOTE: | Tighten the steering stem nut so that the |_ handlebar pivots freely by its own weight, Tighten the steering stem head bolt. 35 — 55 Nem Tightening torque | (3.5 ~5.5 kgm) If any play is still found, inspect the following items and replace the affected parts, if necessary. © Wear of inner or outer races. © Wear of damage of steel balls. © Number of steel balls. © Distortion of steering stem. RIODIC MAINTENANCE AND TUNE-UP PROCEDURES Number of balls Upper 22 pes Lower 18 pesPERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2. FRONT FORK OIL Change Initial 1.000 km (1 month) and Every 3 000 km (3 months) © Support the motorcycle by using the jack or block, Remove the handlebars and ii Take off the front fork cap. Loosen the drain plug. Drain the front fork oil completely and retight- en the drain plug. © Pour specified amount of oil from the top of the inner tube. jon switch. woe ‘Specified amount a (each leg) Fork oil type Fork oil #10 © Tighten the handlebars clamp bolts. Tightening torque Tightening torque jenn Item Nm _[_ kom .2 — 2.0 kg-n e 132520 J Front axle nut 33-51 | 33-51 Brake cam lever bolts (Front and Rear) Bag? | 95-08) CHASSIS BOLTS AND NUTS Front fork upper bracket bolt | 20 — 30 | 20-30 Front fork lower bracket eS 20-30 | 20-30 ———_—____________ Cushion levercenterbolt | 40-60 | 40-60 Exhaust pipe mounting bolt_| 4— 7 | 04-07 © @ ® @ Inspect Initial 1 000 km (1 month) and —w Every 3 000 km (3 months) | Fo Seretoatee heed bot, = L_Every $000km (months) || @ [ianclebar clamp bot 12=20 ‘The nuts and bolts listed are important parts, and [z poorest bolt es they must be in good condition for safety. They o es suininitet) oa 75 Do must be retightened, as necessary, to the specified adie mong bol asia torque with torque wrench, @ | pant eck absorber upper | 49-60 | 40-60 ‘G) | Cushion lever holder bolt 18-28 | 18-28 B [Cushion lever bole 40-60 | 40-60 Rear sh 7 @ | Ree shoek bearer 40-60 | 40-60 | Cushion ever rod bork 1828 | 18-28 G5) Torque link bolt 10-15 | 10-15 GB | Rear axle nut 40-87 | 40-57 | Muffler mounting bolt 10-16 | 10-16 @ ®@2.17 PERIODIC MAINTENANCE AND TUNE-UP PROCEDURESPERIODIC MAINTENANCE AND TUNE-UP PROCEDURES 2.ERVICING ENGINE CONTENTS ENGINE COMPONENTS REMOVAL WITH THE ENGINE IN PLACE: ENGINE REMOVAL... ENGINE DISASSEMBLY ---------------- ENGINE COMPONENTS. INSPECTION © AND SERVICING -- sereeenes B12 ENGINE REASSEMBLY 319341 SERVICING ENGINE ENGINE COMPONENTS REMOVAL WITH THE ENGINE IN PLACE ‘These parts and components can be removed for servicing without dismounting the engine as a whole, Water pump. Clutch Kick starter gear, etc. Magneto Cylinder head, Cylinder, piston Primary gear Oil pump Gear shift shafts etc. ENGINE REMOVAL Before taking the engine out of the frame, wash the engine with a stream cleaner and drain trans- mission oil etc. The procedure of engine removal is sequentially explained in the following steps, and engine installation is effected by reversing the re- moval procedure. ‘© Support the motorcycle by using jack or block. ‘© Take off the radiator cover. ‘@ Remove the radiator cap. © Remove the drain plug and drain the cooling solution. ‘© Remove the seat and frame cover (right and left), © Loosen the fuel tank mounting bolt.SERVICING ENGINE 3.2 © Turn the fuelcock “ON” or “RES” posi ® Disconnect the fuel hose. © Remove the fuel tank. * Loosen the radiator mounting nuts holding with open end wrench and radiator hose clamp screw. * Take off the radiator. * Disconnect the magneto lead wire. ‘© Remove the magneto cover and gearshift lever.SERVICING ENGI ENGINE DISASSEMBLY © Loosen the cylinder head nut and remove the cylinder head. © Loosen the cylinder nut and disconnect the oil hose. ‘@ Remove the cylinder. CAUTION: Place the removed cylinders on the table upside down to prevent distortion of the reed valve stopper. ‘© Remove the piston pin circlip.SERVICING ENGINE 3.6 * Draw out the piston pin by using special tool, | 09910-34510 | Piston pin puller eS * Remove the clutch cover and kick starter lever. NOTE: Do not miss the dowel pi * Loosen the clutch pressure plate bolts by using the special tool. * Take off the spring, pressure plate, drive plate, driven plate and push piece. ® Flatten the lock washer. ® Loosen the clutch sleeve hub nut by using the special tool. 09920-53710 | Clutch sleeve hub holder3.9 SERVICING ENGINE © Remove the rotor by using the special tool. 09930 - 30102 Sliding shaft 09930-30161 | Attachment © Remove the stator. © Remove the oil pump. © Remove the neutral switch. NOTE: Do not lose the spring and the contact pin.SERVICING ENGINE 3-10 * Loosen the crankcase screws. ® Separate the crankcase by using the special tool, 09920 - 13120 Crankcase separator © Take off the oil pump drive gear. © Remove the gear shift fork shaft, gear shift fork, gear shift cam, spring and neutral stopper. © Remove the counter shaft and drive shaft. 4341 SERVICING ENGINE ‘© Remove the crankshaft by hitting with plasctic hammer, DRIVE SHAFT ASSEMBLY © Install the 2nd driven gear with circlip @ . (09900 - 06107 Snap ring pliers © Install the top driven gear circlip (2) and thrust washer @). 09900 - 06107 Snap ring pliers © Install the 3rd driven gear and 4th driven gear with thrust washer @ and circlip @ 09900 - 06107 Snap ring pliers )SERVICING ENGINE © Jnstall the 5th driven gear and circlip @. 09900 - 06107 ‘Snap ring pliers ® Install the low driven gear and washer. ENGINE COMPONENTS INSPECTION AND SERVICING BEARINGS Wash the bearing with cleaning solvent and lubri- cate with motor oil before inspecting. lnspect the play of each bearing inner race by hand while fixing it in the crankease. Rotate the inner race by hand to inspect an ab- normal noise and a smooth rotation. Replace the bearing if there is something unusual, OIL SEALS Damage to the lip (1) of the oil seal may result in leakage of the mixture or oil. Inspect for damage and be sure to replace damaged parts if there are =y, Play PlaySERVICING ENGINE CYLINDER HEAD Using a surface plate and red lead paste or mecha- nist blueing/making dye, check the gasketed sur- face of the cylinder head for flatness. If high and low spots are noted, remove them by rubbing the surface against emery paper (of about # 400) laid flat on the surface plate in a lapping manner. The gasketed surface must be smooth and per- fectly flat in order to secure a tight joint: a leaky joint can be the cause of reduced power output and inereased fuel consumption. Cylinder head warpage Service Limit 0.05 mm 09900 - 21203 Surface plate 09900 - 20806 Thickness gauge CYLINDER The wear of the cylinder wall is determined from diameter reading taken at 15 mm from the top of the cylinder with a cylinder gauge. If the wear thus determined exceeds the limit indicated below, re- work the bore to the next oversize by using a boring machine or replace the cylinder with a new one, Oversize pistons are available in two sizes: 0,5 mm and 1.0 mm oversizes. 09900 - 20508 Cylinder gauge set Service Limit 41,090 mm. After reworking the bore to an oversize, be sure to chamfer the edges of parts and smooth the cham- fered edges with emery paper. To chamfer, use a scraper, taking care not to nick the wall surface. NOTE Minor surface flows on the cylinder wall due | to seizure or similar abnormalities can be cor- rected by grinding the flaws are deep grooves ‘or otherwise persist the cylinder must be reworked with a boring machine to the next oversize.PISTON Decerbon the piston and piston ring grooves, as shown in Fig. After cleaning the grooves, fit the fee and rotate them in their respective grooves ‘tbe sure that they move smoothly. Carbon in the groove is liable to cause the piston fing to get stuck in the groove, and this condition will lead to reduced engine power output. A piston whose sliding surface is badly grooved or scuffed due to overheating must be replaced. Shallow grooves or minor scuff can be removed by sinding with emery paper of about # 400. Cylinder to piston clearance is the difference be- ‘tween piston diameter and bore diameter. Be sure to take the miked diameter at right angles to the piston pin, The value of elevation A) is prescribed to be 23 mm. 09900 - 20202 Micrometer Piston diameter to cylinder to piston clearance determination, The measurement for the bore dia- meter will be made at @ 15 mm from the cylinder top surface. Unit: mm STD Limit Cylinder bore | 41,000— 41,015 | 41.090 [Piston diameter | 40.955 — 40,970 | 40.880 | Cylinder to piston 0.040 0,050 | 0.120 | SERVICING ENGINE 3-14 ‘Smoothing the sliding surface with emery paper.PISTON RINGS Check each ring for end gap, reading the gap with a thickness gauge (Part No. 09900-20803), as shown in Fig. If the end gap is found to exceed the limit, indicated below, replace it with a new one, The end gap of each ring is to be measured with the ring fitted squarely into the cylinder bore and held at the least worn part near the cylinder bot- ‘tom, as shown in Fig. Service Lit 0.75 mm ‘As the piston ring wears, its end gap increases re- ducing engine power output because of the result- ant blow by through the enlarged gap. Here lies the importance of using piston rings with end gaps within the limit. ‘Measure the piston ring free end gap to check the spring tension. Service limit 2.4mm 3.6 mm Fix the piston ring in the piston ring groove, ‘measure the ring side clearance with the thickness ‘gauge while matching the sliding surfaces of piston and ring. S.T.D. 0.02 — 0.06 mm REED VALVE Check the clearance (A) between reed valve and its seat and the dimension @. If the clearance A) is noted to exceed 0.2 mm, replace the reed valve flapping piece. The dimension ® is at least 1 mm. Not! When replacing fl part, apply the | thread lock cement to the screws and tighten |_ it with the torque value 7 — 9 kg-cm.SERVICING ENGINE 3.16 the crankshaft with “V" blocks @. ‘the dial indicator @) at the positions shown s=ad the runout. Runout is total dial reading, ‘= specified to be within the following limit: Limit 0.05 mm, crankshaft runout is often responsible ‘sérormal engine vibration. Such vibration jengine life. OF BIG END BEARING ‘ankshaft with the connecting rod to ‘of rotary motion in the big end. ‘Se rod up and down while holding the rigidly to be sure that there is no rattle V-block set Dial gauge (1/100) e big end of connecting rod can be ‘by checking the movement of the small ‘#24. This method can also check the ex- ‘om the parts of the connecting rod’s sesceeds the limit, connecting rod, crank pin bearing should all be replaced.347 SERVICING ENGINE GEARS AND SHIFTING FORKS Upon disassembling the engine, immediately spect the transmission internals, visually examining the gears for damage and checking the meshed condition of gear teeth. Using a thickness gauge, check the shifting fork clearance in the groove of its gear. (09900 - 20804 Thickness gauge This clearance for each of the three shifting forks play n important role in the smoothness and Positiveness of shifting action. Each fork has its prongs fittted into the annular groove provided in its gear. In operation, there is sliding contact between fork and gear and, when a s! is initiated, the fork pushes the gear axially. Too much a clearance is, therefore, liable to cause the meshed gears to slip apart. If the clearance checked is noted to exceed the limit specified, replace the fork or its gear, or both. CLUTCH DRIVE PLATES AND DRIVEN PLATES Clutch plates in service remain in oily condition as, if they were lubricated with oil, Because of this condition, both drive and driven plates are subject to little wearing action and therefore last much longer. Their life depends largely on the quality of oil used in the clutch and also on the way the clutch is operated. These plates are expendable: they are meant to be replaced when found worn down or distorted to the respective limit: use a caliper to check thick- ness and a thickness gauge and surface plate to check distortion. (09900 - 21203, Surface plate (09900 - 20101 Vernier caliper (09900 - 20804 Thickness gauge | Unit: mm Service limit | Drive plate | Driven plate Thickness 44 = Distortion = 0.10 Claw width a | = _ Shifting fork clearance in the groove Shift fork — groove clearance Service Limit No.1 | for 2nd drive gear | No.2 | for Sth driven gear | 0,50 mm No.3 for top driven gear Checking thickness Checking distortion